Fiber type energy-conducting structures



KR 313659595 [,f jg Jan. 30, 1968 G. A. GRANITSAS ET AL 3,

FIBER TYPE ENERGY-CONDUCTING STRUCTURES Original Filed Dec. 18, 1961- INVENTOR. 6501966 19. GRAN/7545 w BY 4m) 0. cm/vualv W 3,366,506 FIBER TYPE ENERGY-CONDUCTING STRUCTURES George A. Granitsas, Marlboro, Mass, and Harry D.

1 Claim. (Cl. 117-124 ABSTRACT OF THE DISCLOSURE A face plate for a cathode ray tube formed of fused together glass clad energy-conducting fibers; the plate having porosities therein sealed with a network of silicon dioxide.

This is a division of application Ser. No. 159,984 filed Dec. 18, 1961, now Patent 3,279,942.

The present invention relates to energy-conducting structures formed of a plurality of fiber-like elements secured together in side-by-side relation with each other and has particular reference to fused fiber face plates which are hermetically sealed throughout.

Fiber energy-conducting face plates of the type relating more particularly to this invention are formed by bundling a plurality of glass clad fiber elements together in mosaic fashion and heating the resultant array thereof to a temperature suitable for bringing about fusion ofthe fiber elements. During fusion, lateral compressing forces are usually applied to the array of fiber elements in an attempt to close off as many voids therebetween as possible. This practice produces structures whose fiber elements are generally quite well integrated but very often minute crevices or other porosities remain unsealed between some of the fiber elements. Consequently, in normal production,

-a relatively large percentage of the resultant fused structures are permeable to air or gases particularly when subjected to pressure or the pull of a vacuum and must be rejected as unsuitable for use as face plates on devices such as cathode ray tubes or the like wherein such face plates must be vacuum tight.

Numerous attempts have been made to overcome the relatively high rejection rate of face plate structures of the above character, and, for the most part, such attempts have'dealt with variations in the methods of making the initial assembly and techniques for applying greater than usual compressing forces on the fiber elements. Techniques which rely on temperatures and pressures in the order of those required to assure a complete vacuum seal between all fiber elements most generally cause the individual fiber elements to become impaired by overheating and/or seriously distorted under the pressures applied with the consequence of producing a vacuum-tight but otherwise inferior product.

Other conventional sealing techniques involve the application of superficial layers of sealing material such as glass or the like to the energy receiving and/or emitting surfaces of the fiber face plate structures. This approach to the problem'is difiicult and costly to perform and such sealing layers are usually, in one way or another, detrimental to the energy-conducting properties of the end product.

This invention provides a simple, inexpensive and exceptionally reliable process for sealing crevices or other porosities between the fiber elements of fused structures wherein the above-mentioned shortcomings and other obvious difiiculties inherent in conventional practices of this nature are obviated.

nited States Patent 3,366,5idfi Patented Jan. 30, 968

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Another object is to provide a sealing medium for the purpo es of this invention which when applied to the fiber-type structure will readily permeate existing crevices, interstices or other porosities therein and when cured will permanently seal said porosities and be capable of withstanding temperatures in the order of those which might be required to perform subsequent edge fusing or other similar operations on said structure during its assembly with articles intended to receive the same.

Another object is to provide fiber face plate structures which are vacuum sealed with an impervious silica network.

Other objects and advantages of the invention will become apparent from the following description when taken in conjunction with the accompanying drawings in which:

FIG. 1 is a partially broken away side elevational view of a cathode ray tube having a fused face plate of the type relating more particularly to this invention;

FIG. 2 is a greatly enlarged longitudinal cross-section of an energy conducting fiber element which is representative of a type commonly used in the fabrication of cathode ray tube face plates or the like;

FIG. 3 is a greatly enlarged fragmentary plan view of the fiber face plate shown in FIG. 1 as it might appear before treatment in accordance with the invention;

FIGS. 4 and S are diagrammatic illustrations of means and method for carrying out the process of the invention; and

FIG. 6 is a fragmentary cross-sectional view taken on line 66 of FIG. 1 shown on a greatly enlarged scale so as to clearly illustrate the cross-sectional structure of the face plate and the results of treatment thereof in accordance with this invention.

In FIG. 1 there is shown a fiber faceplate 10 which is representative of the general type of structures to which the vacuum sealing process of the invention is particularly applicable. The face plate 10 in this instance is intended to receive and transfer energy through the envelope ll of a cathode ray type of electron tube 14.

In such electron tubes, a vacuum is provided within the envelope l2 and must be sustained throughout the expected life of the tube. Leakage in tube envelopes of the above character can be relatively easily prevented at the joinders made between the fiber face plate and the envelope proper by the practice of conventional glass fusing and/or glass soldering techniques. However, in view of the fact that fiber structures such as the face plate it are usually made up of literally thousands of very fine individual fiber elements 1e (see FIGS. 2 and 3) which are joined by fusion in side-by-side relation with each other, it is extremely difficult to provide a complete vac uum seal between each and every fiber element at the time the face plate is fabricated.

In conventional optical or light-conducting face plate structures the fiber elements 16 usually each embody a core section ill (see FIG. 2) of optical glass or the like having a relatively high index of refraction surrounded; by a relatively thin cladding Zlll of glass having a relatively low index of refraction. A typical fiber construction might, for example, embody a core 18 formed of optical fiint glass having an index of refraction of approximately from 1.66 to 1.75 with a cladding 20 formed of crown or soda lime glass having an index of refraction of approximately 1.52. The cladding is generally of a thickness approximately that of the overall fiber diameter but may vary considerably from this figure in certain cases. It is pointed out that the fiber elements 16 might also be provided with core parts formed of special glasses characterized to be primarily transmissive to selected regions of the spectrum and the claddings may be formed of glasses having controlled light-absorbing or other special characteristics. The fiber elements 16 may be of the monofilameut type each having a single core part and cladding as illustrated or they might be of the so-eallcd multifibcr" type which, in itself, is a single fiber containing a plurality of energyconducting core: each completely surrounded by cladding material.

The monofilament type of fibers may, for example, be formed by placing a rigid heat-softenable rod-like member of energy-conducting material within a tubular nem be; of hcat-softenable material wherein the rod and tribe members are of the character desired of the respective core and cladding parts of the fibers and the assembly of the members is heated and drawn to a fiber size. Alternatively similar materials might be treated to a ilowable state and extruded simultaneotrsly, one surrounding the other to form fiber elements such as 16. These techniques are set forth in detail in patents numbered 2,980,957 and 2,992,517 respectively. Multifibers are formed by drawing a bundle of clad monofilaments, as a unit, down to a fiber size as shown, for example, in Patent Number 2,992,- 516.

While an optical or light-conducting fiber 16 has been shown for purposes of illustration in the drawings, it should be understood that wire type fibers may be used in the fabrication of face plates for purposes of receiving and transferring electrical rather than light energy. In such a case, the core 18 in H6. 2 would be formed of a metallic material and the glass cladding would, most likely, be somewhat thicker than illustrated.

For cathode ray tube face plates, fibers ranging in size from 3 to 4 microns in diameter to 3 or 4 mils or larger in diameter might be used. Smaller fibers, in general, produce better resolution in transferring image energy. For the purposes of transferring optical images, however, the fibers should not be as small in diameter as to approach the wavelength of the particular light which is to be trans ferred thereby.

In forming the fused structure of the face plate 10, a. plurality of fiber elements 16 of preselected size and character are placed in side-by-side bundled relation with each other and heated to fusible temperatures while the bundle is simultaneously compressed to squeeze the fibers into intimate interfitting relation with each other as shown in FIG. 3. The fiber elements 16 may be initially circular, square, hexagonal or of any desired cross-sectional configuration.

The actual details involved in forming the face plate structure 10 will not be dealt with herein since this in vention relates to the treatment of fused structures of this general character which may have been formed to this point by any technique whether conventional or otherwise.

As pointed out nereinabove, under the best of eonditions fused fiber structures such as the face plate 10 cannot be consistently formed to be vacuum-tight and, consequently, leaks through the structures usually result from interstices 22 (see FIG. 3) between the fiber elements 16 which do not become completely closed at thetime the fiber structure is fused. These interstices 22 are usually very minute and many times smaller in cross-sectional size than the actual size of the fiber elements 16 which make up the face plate 10 so that they are not readily detectable by visual inspection. Nevertheless, under the pull of a vacuum equivalent to that provided within cathode ray tubes or the like, such face plates are found to leak. That is, air will permeate through the interstices, however small they may bc. Minute fissures in the face platestructures may also contribute to troublesome leak prob lems in fused fiber face plate structures and while inter slices such as mentioned above or fissures or other similar porositics may not be and normally are not corrsequential with regard to the energy-conducting eapabilities or physical strength of the face plate structures, they do render the face plates inferior and as such unsuitable for use on items such as cathode ray tubes or the like which require positive vacuum seals.

in accordance with this invention, interstices, fissures and/or other porosities in fused fiber plates are sealed with a silica network as follows:

A fresh silicic acid solution is prepared and the face plate structure to be treated is immersed therein for r. period of time sufficient to allow the solution to porosities therein. The face plate structure is moved from the silicic acid solution, dried at a r C. for from l5 to 45 minutes and thereafter beaten to a temperature of from approitiinately C. to Zlit'i" t}. tor from A: to 1 hour to cure or promote acceleratmt ran lyrnerization of the silicic acid in the porositics and its form a silica (SiO networlr. which functions to seal sairl porositios.

in Ht]. 4 the face plate it? is illustrated as being int rersed in a silicic acid solution ill l within a container 21d and in FIG. 5 a curing oven Jill is illustrated diagrauu matically and in which the face plate lrli is placed for drying and curing. Heat is produced in the oven means of conventional electrical resistance element the like which are electrically connected by lea: through :1 conventional heat control unit M to a source of current 36. The unit 34 which might, for ertamplc, operate in response to a thermocouple or the tilt. functions to provide and maintain the oven at a proper temperature for bringing about an accelerated polymerization of the uilicic acid.

Referring in more detail to the process of the invention, it is pointed out that, as mentioned above, a fresh solution of silicic acid is used. The terms fresh solution" or freshly prepared solution" as used herein are intended to mean a soltuion which is used immediately or nah-- in a period of no more. than two or three days after its preparation. The use of a fresh solution of silicic acid is esscrrtal in instances where the porosities in the face plate lttl are minute as is most generally the case. A freshly prepared solution of silicic acid wherein the concentration of polymer is at a minimum will penetrate or be imbibed readily by capillary action into the ptiirnsities while commercial silicic acid solutions wherein the molccular size of the polymer is inl'icrerrtly larger, even at the minimum concentration which is available, will not adequately penetrate into the smaller porosities. Since rela: tively large interstices or cavities or the like are infrequent in conventionally fused fiber structures of the above char :rctcr wherein the art of fusing is refined to the point or? being able to avoid occurrence of the saute, present day dillicutties relate almost entirely to small porosities which must be sealed. Thus a fresh silicic acid solution is, for all practical purposes, essential to the process of this in 'errtion.

It is well known that a silicic acid solution such normal silicic acid SitOI l), may he prepared in various ways such as, for example, by treating a solution of potassium or sodium silicate with hydrochloric acid and a solution of ortho silicic acid in alcohol may be prepared by combining tetra ethyl ortho silicate, ethyl aim-- hol and hydrochloric acid in the following related proportions of ingredients:

Parts (EtOhSi lull EtOH .s u.. W WM... 45% 0.1 N HCl M The above-given related prortz-ortious are such that the not stitueuts are substantially fully reacted in the resultant solution and While these proportions may be varied to include more or less of one or more of the ingredients set forth above, any substantial variation from the ziroportions of ingredients set forth above by way of example will serve no useful purpose.

The solution of ortho silicic acid in alcohol when freshly prepared is preferred for carrying out the sealing process of the invention. However, it should be understood that silicic acid solutions prepared from other known constituents might be used.

Specific examples of actual treatment of fiber-type face plate structures indicated as sample I and sample II are given hereinafter wherein the leak rate rate due to porosities in the structures was determined before and after treatment by means of a standard helium leak detector which is often referred to as a Mass Spectrometer Leak Detector. Such leak detectors are well' known laboratory testing instruments and require no further description herein.

SAMPLE 1 Leak rate prior to treatment-2.8 l0-" c.

um/second.

heli- Treatment (a) Immersed overnight in freshly prepared solution of ortho silicic acid in alcohol.

(b) Heated to approximately 35 C. until dry.

(c) Baked 6 hour at 190 C.

Test

Leak rate 1.1 X 10 cc. helium/second.

Retreated Same as (a), (-b), and (0) above.

Test No leak. SAMPLE II Treatment (a) Immersed overnight in freshly prepared solution of ortho silicic acid in alcohol.

(b) Heated approximately 30 minutes at approximately 35 C. to dry.

(c) Baked /z hour at 190 C.

Test

No leak.

It "is pointed out that the solution of ortho silicic acid in alcohol which inherently contains some water and which was used in the treatment of samples I and II was prepared as outlined hereinabove and the above-disclosed moderate drying temperatures are applied to the face plate structure primarily to volatilize and dispel the more volatile constituents (ethyl alcohol and water) of the silicic acid solution at a moderate rate so'as not to force the silicic acid out of they pores of the structure being treated. The subsequently applied higher temperatures accelerates polymerization of the silicic acid and dries off the water thus formed, leaving substantially only a silica (Si0,) network 39 (see FIG. 6) in the porosities of the fiber structure.

The porosities may be in the form of interstices extending between two adjacent fiber elements 16 as shown by the reference numeral 22 in FIGS. 3 and 6 or in the form of fissures, one of which is also shown in FIG. 6 by the reference numeral 40. Other types of porosities may embody interjoining interstices '22 and/or fissures 40 which provide passageways through the fiber structure of the face plate 10. It is pointed out that the showing in FIG. 6 is greatly exaggerated in size for purposes of illus tration, and a fissure such as shown by numeral 40, if existent, might not extend completely through the structure as shown, but might for example extend somewhat laterally into communication with one or more of the interstices 22.

As it is evident from the foregoing, the process of the invention may be repeated any number of times to build up a silica network 39 which eventually completely closes otf larger porosities. Furthermore, the required time of immersion of the face plate in the silicic acid solution should be such as to cause all porositiestobecome substantially completely filled with the silicic acid solution. However, since the minimum immersion time required to accomplish this result is dependent upon the size of porosities to be'filled, which porosities may vary in size throughout each fiber structure, and the sireof porosities can only be estimated to be of a size in accordance with the leak rate of the structure, it is preferableto initially immerse the structure in the silicic acid solution for an extended period (for example, overnight) when possible and particularly when the initial leak rate is in the order of that given in sample I above. After drying and baking in the manner outlined above, a test for leaks will determine whether or not repeated treatment is required for producing a positive vacuum seal. As. it is evident from the above-outlined treatment of sample II, a subsequent immersion period or periods of only a few minutes each may be adequate. It should be understood that the suggested overnight immersion period is not essential to the process of the invention and that shorter periods of immersion such as from 15 to 45 minutes may be used wherein each immersion period is followed by the drying and baking periods set forth hereinabove. Fiber struc tures initially having a low order leak rate such as, for example, l.l l0-" cc. helium/second or less as determined with a standard helium leak detector usuallyrequire immersion periods of less than 1 hour followed by drying and baking as outlined hereinabove for the accomplishment of a substantially perfect vacuum-tight seal.

Fiber-type structures of the above character which have been vacuum-sealed in accordance with this inven tion can be reheated to relatively high temperatures for purposes of edge sealing the same in tube envelopes or the like as shown in FIG. 1 without detriment to the etfectiveness of the seal produced by the silica network therein. By way of example, the above-described samples I and II were reheated to 850 F. for approximately 1 hour each and when cooled and tested no leak rate was indicated.

From theforegoing, it can be seen that novel means and method have been set forth for accomplishing all of the obects and advantages of the invention. Nevertheless, it should be apparent that many changes in the steps of the method and other details set forth hereinabove may be made without departing from the spirit of the inven tion as expressed in the accompanying'claim. The inve'n tion, therefore, is not to be limited to the exact matters shown and described as only preferred matters have been given by way of illustration.

We claim:

-1. A fiber energy-conducting face plate for a cathode 3,366,506 7 8 I ray tube comprising a multiplicity of individually glass References Cited clad energy-conducting fibers fused together in side-by- UNITED STATES PATENTS side relationship with corresponding opposite ends thereof forming energy receiving and emitting faces respectively 2'985784 5/1961 MacNemeof said plate there being undesired porosities in said plate 5 141,105 7/1964 courmey'prau f" 390*96 X extending between said faces and a network of silicon 3,195,219 7/1965 Woodcock at dioxide in said porosities rendering each impervious to 3226589 12/1965 wwdcockair and gases when under the influence of a vacuum at least equivalent to that normally produced within a ALFRED LEAVHT Pr'mary Exammer" cathode ray tube. 10 H. COHEN, Assistant Examinen 

